Surgical robotic tools, data architecture, and use

ABSTRACT

Robotic surgical tools, systems, and methods for preparing for and performing robotic surgery include a memory mounted on the tool. The memory can perform a number of functions when the tool is loaded on the tool manipulator: first, the memory can provide a signal verifying that the tool is compatible with that particular robotic system. Secondly, the tool memory may identify the tool-type to the robotic system so that the robotic system can reconfigure its programming. Thirdly, the memory of the tool may indicate tool-specific information, including measured calibration offsets indicating misalignment of the tool drive system, tool life data, or the like. This information may be stored in a read only memory (ROM), or in a nonvolatile memory which can be written to only a single time. The invention further provides improved engagement structures for coupling robotic surgical tools with manipulator structures.

CROSS-REFERENCES TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Appl.No. 60/111,713 filed on Dec. 8, 1998, (Attorney Docket No. 17516-003200)the entirety of which is herein incorporated by reference.

BACKGROUND OF THE INVENTION

[0002] This invention relates to robotically assisted surgery, and moreparticularly provides surgical tools having improved mechanical and/ordata interface capabilities to enhance the safety, accuracy, and speedof minimally invasive and other robotically enhanced surgicalprocedures.

[0003] In robotically assisted surgery, the surgeon typically operates amaster controller to remotely control the motion of surgical instrumentsat the surgical site. The controller may be separated from the patientby a significant distance (e.g., across the operating room, in adifferent room, or in a completely different building than the patient).Alternatively, a controller may be positioned quite near the patient inthe operating room. Regardless, the controller will typically includeone or more hand input devices (such as joysticks, exoskeletol gloves,master manipulators, or the like) which are coupled by a servo mechanismto the surgical instrument. More specifically, servo motors move amanipulator or “slave” supporting the surgical instrument based on thesurgeon's manipulation of the hand input devices. During an operation,the surgeon may employ, via the robotic surgery system, a variety ofsurgical instruments such as tissue graspers, needle drivers,electrosurgical cautery probes, etc. Each of these structures performsfunctions for the surgeon, for example, holding or driving a needle,grasping a blood vessel, or dissecting, cauterizing, or coagulatingtissue.

[0004] This new method of performing robotic surgery has, of course,created many new challenges. One such challenge is that a surgeon willtypically employ a significant number of different surgical instrumentsduring each surgical procedure. The number of independent surgicalmanipulators will often be limited due to space constraints and cost.Additionally, patient trauma can generally be reduced by eliminating thenumber of tools used at any given time. More specifically, in minimallyinvasive procedures, the number of entry ports into a patient isgenerally limited because of space constraints, as well as a desire toavoid unnecessary incisions in the patient. Hence, a number of differentsurgical instruments will typically be introduced through the sametrocar sleeve into the abdomen during, for example, laparoscopicprocedures. Likewise, in open surgery, there is typically not enoughroom adjacent the surgical site to position more than a few surgicalmanipulators, particularly where each manipulator/tool combination has arelatively large range of motion. As a result, a number of surgicalinstruments will often be attached and detached from a single instrumentholder of a manipulator during an operation.

[0005] Published PCT application WO98/25666, filed on Dec. 10, 1997 andassigned to the present assignee (the full disclosure of which isincorporated herein by reference) describes a MulticomponentTelepresence System and Method which significantly improves the safetyand speed with which robotic surgical tools can be removed and replacedduring a surgical procedure. While this represents a significantadvancement of the art, as is often true, still further improvementswould be desirable. In particular, each tool change which occurs duringa surgical procedure increases the overall surgery time. While stillfurther improvements in the mechanical tool/manipulator interface mayhelp reduce a portion of this tool change time, work in connection withthe present invention has shown that the mechanical removal andreplacement of the tool may represent only one portion of the totalinterruption for a tool change. U.S. Pat. No. 5,400,267 describes amemory feature for electrically powered medical equipment, and is alsoincorporated herein by reference.

[0006] As more and more different surgical tools are provided for usewith a robotic system, the differences between the tool structures (andthe interaction between the tool and the other components of the roboticsystem) become more pronounced. Many of these surgical tools will haveone or more degrees of motion between the surgical end effectors and theproximal interface which engages the tool to the holder of themanipulator. The desired and/or practicable ranges of motion for anelectrosurgical scalpel may be significantly different than those of aclip applier, for example. Work in connection with the present inventionhas found that even after a tool is properly placed on the surgicalmanipulator, the time involved in reconfiguring the robotic system totake advantage of a different tool, and to perfect the mastercontroller's effective control over the degrees of motion of the tool,may add significantly to the total tool change delay.

[0007] In light of the above, it would be desirable to provide improvedrobotic surgery tools, systems, and method. It would further bedesirable to provide techniques for reducing the total delay associatedwith each tool change. It would be especially desirable if theseenhanced, and often more rapid, robotic tool change techniques resultedin still further improvement in the safety and reliability of thesepromising surgical systems.

SUMMARY OF THE INVENTION

[0008] The present invention generally provides improved roboticsurgical devices, systems, and methods for preparing for and performingrobotic surgery. The robotic tools of the present invention will oftenmake use of a memory structure mounted on a tool, manipulator arm, ormovable support structure. The memory can, for example, perform a numberof important functions when a tool is loaded on the tool manipulator:first, the memory can provide a signal verifying that the tool iscompatible with that particular robotic system. Secondly, the toolmemory may identify the tool-type (whether it is a scalpel, needlegrasper, jaws, scissors, clip applier, electrocautery blade, or thelike) to the robotic system so that the robotic system can reconfigureits programming to take full advantage of the tools' specializedcapabilities. This tool-type data may simply be an identification signalreferencing further data in a look-up table of the robotic system.Alternatively, the tool-type signal provided by the tool may define thetool characteristics in sufficient detail to allow reconfiguration ofthe robotic programming without having to resort to an external table.Thirdly, the memory of the tool may indicate tool-specific information,including (for example) measured calibration offsets indicatingmisalignment between the tool drive system and the tool end effectorelements, tool life data (such as the number of times the tool has beenloaded onto a surgical system, the number of surgical proceduresperformed with the tool, and/or the total time the tools has been used),or the like. The information may be stored in some form of non-volatilememory such as one-time programmable EPROM, Flash EPROM, EEPROM,battery-backed-up SRAM, or similar memory technology where data can beupdated and retained in either a serial or random access method, or withany of a wide variety of alternative hardware, firmware, or software.The invention further provides improved engagement structures forcoupling robotic surgical tools with manipulator structures.

[0009] In a first aspect, the invention provides a robotic surgical toolfor use in a robotic surgical system. The robotic surgical system has aprocessor which directs movement of a tool holder. The tool comprises aprobe having a proximal end and a distal end. A surgical end effector isdisposed adjacent the distal end of the probe. An interface is disposedadjacent to the proximal end of the probe. The interface can bereleasably coupled with the tool holder. Circuitry is mounted on theprobe. The circuitry defines a signal for transmitting to the processorso as to indicate compatibility of the tool with the system.

[0010] The tool will often comprise a surgical instrument suitable formanipulating tissue, an endoscope or other image capture device, or thelike. Preferably, the signal will comprise unique tool identifier data.The processor of the robotic surgical system may include programming tomanipulate the tool identifier according to a predetermined function oralgorithm so as to derive verification data. The signal transmitted tothe processor will often include the verification data. Alternativecompatibility signals may include a signal which is listed in a tableaccessible to the processor, an arbitrary compatibility data string, orthe like.

[0011] In another aspect, the invention provides a robotic surgicalcomponent for use in a robotic surgical system having a processor and acomponent holder. The component comprises a component body having aninterface mountable to the component holder. The body supports asurgical end effector, and a drive system is coupled to the body formoving the end effector per commands from the processor. Circuitry ismounted on the body and defines a signal for transmitting to theprocessor. The signal may indicate compatibility of the component withthe system, may define a component type of the component, may indicatecoupling of the component to the system, and/or may indicate calibrationof the component. Typically, the component will comprise a surgicaltool, a manipulator arm, a pre-positioning linkage supporting themanipulator arm, or the like.

[0012] In another aspect, the invention provides a method for installinga robotic surgical component in a robotic surgical system. The methodcomprises mounting the component to a component holder. A signal istransmitted from the component to a processor of the robotic surgicalsystem. The component is articulated in response to the signal percommands of the processor.

[0013] In many embodiments, compatibility of the component with therobotic surgical system will be verified using the signal transmittedfrom the component to the processor. This can be accomplished byproviding unique identification data on the component, and derivingverification data from the identification data according to analgorithm. The verification data is stored with a memory of thecomponent, the signal transmitted to the processor including both theidentification and verification data. The algorithm may then beperformed on the transmitted unique identification data with theprocessor, and the results compared with the verification data.Advantageously, this method can take advantage of unique identificationdata which is often unalterably stored in a memory of commerciallyavailable integrated circuits.

[0014] In another aspect, the invention provides a robotic surgical toolfor use in robotic surgical systems having a processor. The toolcomprises a shaft having a proximal end and a distal end. A surgical endeffector is disposed adjacent the distal end of the shaft. The endeffector has a plurality of degrees of motion relative to the proximalend. An interface is disposed adjacent the proximal end of the shaft.The interface can be releasably coupled with a robotic probe holder. Theinterface comprises a plurality of driven elements. A plurality of tooldrive systems couple the driven elements to the degrees of motion of theend effector. The tool drive system has calibration offsets between anominal relative position of the end effector and the driven elements,and a measured relative position of the end effector and drivenelements. A memory stores data indicating the offsets. The memory iscoupled to the interface so as to transmit the offsets to the processor.

[0015] In yet another aspect, the invention provides a robotic surgicalsystem comprising a plurality of tools of different tool-types. Eachtool comprises an elongate shaft with a cross-section suitable forintroduction into an internal surgical site within a patient body via aminimally invasive opening. A distal surgical end effector is coupled tothe shaft by at least one joint. The joint is drivingly coupled to aproximal interface by a tool drive system. Circuitry of the tooltransmits a tool-type via the interface. The tool types may optionallydiffer in at least one characteristic such as joint geometry, endeffector geometry, drive system characteristics, end effector or drivesystem strength, or the like. The system also includes a roboticmanipulator including a linkage supporting a tool holder. The toolholder releasably receives the interface. A manipulator drive motordrivingly engages the linkage so as to move the tool holder relative tothe opening and position the shaft within the surgical site. A tooldrive motor is coupled to the tool holder so as to drivingly engage thetool drive system and articulate the joint. A processor is coupled tothe tool holder. The processor has programming that effects a desiredmovement of the end effector by transmitting drive signals to the tooldrive motors of the manipulator. The processor reconfigures the programfor the different joint geometries based on the tool-type signals.

[0016] In another aspect, the invention provides a robotic surgicalsystem comprising a surgical tool having a surgical end effector and aninterface. A manipulator assembly has a base and a tool holder forreleasably engaging the interface. A plurality of tool engagementsensors are coupled to the tool holder. Each tool sensor produces asignal when the interface engages the holder. A processor is coupled tothe tool engagement sensors. The processor has a tool change mode and atissue manipulation mode. The processor requires tool signals from eachof the sensors before changing the tool change mode to the tissuemanipulation mode. The processor remains in the tissue manipulation modewhen at least one, but not all, of the tool signals is lost.

[0017] The tools used in robotic surgery will be subjected tosignificant structural stress during use. The stress may result intemporary loss of an engagement signal from an engagement sensor. Byproviding at least two, and preferably three engagement sensors, thesurgical procedure can continue safely with the loss of an engagementsignal from an individual sensor so long as the system can still verifyproper engagement between the manipulator and tool. This arrangementresults in a robust tool engagement sensing system that avoids frequentdelays during the surgical procedure as might occur from the loss of anindividual signal.

[0018] In yet another aspect, the invention provides a robotic surgicalsystem comprising a manipulator assembly having a base and tool holderwhich moves relative to the base. The tool holder has a plurality ofdrive elements. A sterile drape covers at least a portion of themanipulator. A sterile tool has a proximal interface and distal endeffector. The distal end effector has a plurality of degrees of motionrelative to the proximal interface. The degrees of motion are coupled todrive elements of the interface. An adapter is disposed adjacent thesterile drape between the holder and the interface. The adaptercomprises a plurality of movable bodies. Each movable body has a firstsurface driven by the drive elements of the holder, and a second surfacedriving the driven elements of the tool.

[0019] In yet another aspect, the invention provides a robotic surgicaltool for use with a robotic manipulator having a tool holder. The toolholder has magnetically actuatable circuitry. The tool comprises a probehaving a proximal end and a distal end. A surgical end effector isdisposed adjacent the distal end of the probe. An interface adjacent theproximal end of the probe is releasably coupleable with the holder. Theinterface comprises a magnet positioned so as to actuate the circuitryof the holder.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020]FIG. 1 illustrates a robotic surgical procedure in which a surgeonat a master station directs movement of robotic surgical tools effectedby a slave manipulator, and shows an assistant preparing to change atool mounted to a tool holder of the slave.

[0021]FIG. 2 is a perspective view of a robotic surgical arm cart systemin which a series of passive set-up joints support robotically actuatedmanipulators (typically, the center arm would support a camera).

[0022]FIG. 2A is a perspective view of a robotic surgical manipulatorfor use in the cart system of FIG. 2.

[0023]FIGS. 2B and C are side and front views, respectively, of thelinkage of the robotic manipulator of FIG. 2, showing how themanipulator maintains a remote center of rotation along a shaft of thesurgical tool.

[0024]FIGS. 3 and 3A are perspective views of exemplary cart structureswith positioning linkages which support the robotic manipulators in thesystem of FIG. 2.

[0025]FIG. 4 is a perspective view of an exemplary tool according to theprinciples of the present invention.

[0026]FIGS. 4A and B are schematic views of alternative drive systemsfor the tool of FIG. 4.

[0027]FIGS. 5A through H are illustrations of a variety of surgical endeffectors of differing tool-types.

[0028]FIG. 6 illustrates the mechanical and electrical interface of thetool of FIG. 4.

[0029]FIGS. 7A through E illustrate an adapter for coupling theinterface of FIG. 6 to the surgical manipulator.

[0030]FIGS. 7G through I illustrate the adapter of FIGS. 7A through Emounted to a holder or carriage of the manipulator.

[0031]FIGS. 7J through L illustrate the holder, its driving elements,and its electrical contacts.

[0032]FIG. 8 is a wiring diagram for the tool of FIG. 4, the adapter ofFIG. 7A-E, and related components of the robotic system.

[0033]FIGS. 8A and B are rear and front views of the master console,respectively.

[0034]FIG. 9 is a functional block diagram schematically illustratingthe signal path hardware of the tool change system.

[0035]FIG. 10 is a schematic diagram illustrating the interactionbetween the software modules related to tool change.

[0036]FIG. 11 is a logic flow chart illustrating an exemplary method forsensing engagement of a tool with the manipulator.

[0037]FIG. 12 is a flow diagram illustrating how the tool engagementsignals are used to change the operating state of the robotic system.

[0038]FIG. 13 illustrates the tool engagement method steps initiated bythe processor in response to a change in operating state during toolchanges.

[0039]FIGS. 14A through C illustrate mounting of the adapter of FIGS. 7Athrough E to a manipulator arm, and of mounting the tool of FIG. 4 ontothe adapter.

[0040]FIG. 15 schematically illustrates an exemplary tool compatibilityverification algorithm according to the principles of the presentinvention.

DESCRIPTION OF THE SPECIFIC EMBODIMENTS

[0041] The present invention provides robotic surgery systems, devices,and methods. Robotic surgery will generally involve the use of multiplerobotic arms. One or more of the robotic arms will often support asurgical tool which may be articulated (such as jaws, scissors,graspers, needle holders, microdissectors, staple appliers, tackers,suction/irrigation tools, clip appliers, or the like) or non-articulated(such as cutting blades, cautery probes, irrigators, catheters, suctionorifices, or the like). One or more of the robotic arms will often beused to support one or more surgical image capture devices such as anendoscope (which may be any of the variety of structures such as alaparoscope, an arthroscope, a hysteroscope, or the like), oroptionally, some other imaging modality (such as ultrasound,fluoroscopy, magnetic resonance imaging, or the like). Typically, therobotic arms will support at least two surgical tools corresponding tothe two hands of a surgeon and one optical image capture device.

[0042] The present invention will find application in a variety ofsurgical procedures. The most immediate applications will be to improveexisting minimally invasive surgical procedures, such as coronary arterybypass grafting and mitral and aortic valve repair and/or replacement.The invention will also have applications for surgical procedures whichare difficult to perform using existing minimally invasive techniques,such as Nissen Fundoplications. Additionally, it is anticipated thatthese surgical systems will find uses in entirely new surgeries thatwould be difficult and/or impossible to perform using traditionally openor known minimally invasive techniques. For example, by synchronizingthe movements of the image capture device and/or surgical tools with atissue undergoing physiological movement (such a beating heart), themoving tissue may be accurately manipulated and treated without haltingthe physiological movement. Additional potential applications includevascular surgery (such as for the repair of thoracic and abdominalaneurysms), general and digestive surgeries (such as cholecystectomy,inguinal hernia repair, colon resection, and the like), gynecology (forfertility procedures, hysterectomies, and the like), and a wide varietyof alternative procedures.

[0043] Referring now to FIG. 1, the robotic surgical system 10 generallyincludes master controller 150 and a robotic arm slave cart 50. Mastercontroller 150 generally includes master controllers (not shown) whichare grasped by the surgeon and manipulated in space while the surgeonviews the procedure views a stereo display. The master controllers aremanual input devices which preferably move with six degrees of freedom,and which often further have an actuatable handle for actuating tools(for example, for closing grasping saws, applying an electricalpotential to an electrode, or the like). In this embodiment, the mastercontrol station 150 also includes a processor, as will be described inmore detail hereinbelow.

[0044] Robotic arm cart 50 is positioned adjacent to patient body P andmoves tools having shafts. The shafts extend into an internal surgicalsite within the patient body via openings O. As illustrated in FIG. 1,one or more assistant may be present during surgery to assist thesurgeon, particularly during removal and replacement of tools. Roboticsurgery systems and methods are further described in co-pending U.S.patent application Ser. No. 08/975,617, filed Nov. 21, 1997, the fulldisclosure of which is incorporated herein by reference.

[0045] Robotic arm cart 50 is shown in isolation in FIG. 2. Cart 50includes a base 52 from which three surgical tools 54 are supported.More specifically, tools 54 are each supported by a series of manuallyarticulatable linkages, generally referred to as set-up joints 56, and arobotic manipulator 58. It should be noted that these structures arehere illustrated with protective covers extending over much of therobotic linkage. It should be understood that these protective coversare optional, and may be limited in size or entirely eliminated in someembodiments to minimize the inertia that is manipulated by the servomechanism, to limit the volume of moving components so as to avoidcollisions, and to limit the overall weight of cart 50.

[0046] Cart 50 will generally have dimensions suitable for transportingthe cart between operating rooms. The cart will typically fit throughstandard operating room doors and onto standard hospital elevators. Thecart should have a weight and wheel (or other transportation) systemthat allows the cart to be positioned adjacent an operating table by asingle attendant. The cart should have sufficient stability in thetransport configuration to avoid tipping at minor discontinuities of thefloor, and to easily withstand overturning moments that will be imposedat the ends of the robotic arms during use.

[0047] Referring now to FIGS. 2A-C, robotic manipulators 58 preferablyinclude a linkage 62 that constrains movement of tool 54. Morespecifically, linkage 62 includes rigid links coupled together byrotational joints in a parallelogram arrangement so that tool 54 rotatesaround a point in space 64, as more fully described in issued U.S. Pat.No. 5,817,084, the full disclosure of which is incorporated herein byreference. The parallelogram arrangement constrains rotation to pivotingabout an axis 64 a, sometimes called the pitch axis. The linkssupporting the parallelogram linkage are pivotally mounted to set-upjoints 56 so that tool 54 further rotates about an axis 64 b, sometimescalled the yaw axis. The pitch and yaw axes intersect at the remotecenter 64, which is aligned along a shaft 66 of tool 54.

[0048] Tool 54 has still further driven degrees of freedom as supportedby manipulator 58, including sliding motion of the tool along insertionaxis 64 (the axis of shaft 66), sometimes referred to as insertion. Astool 54 slides along axis 64 c relative to manipulator 58, remote center64 remains fixed relative to base 68 of manipulator 58. Hence, theentire manipulator is generally moved to re-position remote center 64.

[0049] Linkage 62 of manipulator 58 is driven by a series of motors 70.These motors actively move linkage 62 in response to commands from aprocessor. Motors 70 are further coupled to tool 54 so as to rotate thetool about axis 66, and often to articulate a wrist at the distal end ofthe tool about at least one, and often two, degrees of freedom.Additionally, motors 70 can be used to actuate an articulatable endeffector of the tool for grasping tissues in the jaws of a forceps orthe like. Motors 70 may be coupled to at least some of the joints oftool 54 using cables, as more filly described in U.S. Pat. No.5,792,135, the full disclosure of which is also incorporated herein byreference. As described in that reference, the manipulator will ofteninclude flexible members for transferring motion from the drivecomponents to the surgical tool. For endoscopic procedures, manipulator58 will often include a cannula 72. Cannula 72 supports tool 54,allowing the tool to rotate and move axially through the central bore ofthe cannula.

[0050] As described above, manipulator 58 is generally supported bypassive set-up joints 56. Exemplary set-up joint structures areillustrated in FIG. 3. The exemplary set-up joint system includes threetypes of structures. First, a vertical column 80 supports verticallysliding joints 82 that are used to position manipulator 58 along thevertical or Z axis. Second, rotary joints 84 separated by rigid links 86are used to horizontally position manipulators 58 in the X-Y plane.Third, another series of rotary joints 84 mounted adjacent a manipulatorinterface 88 rotationally orients the manipulators.

[0051] The structure of column 80, vertical sliding joints 82, and base52 can be understood with reference to FIG. 3. Beginning with base 52,the base will generally distribute the weight of the robotic structuresand the forces imposed on the robotic arms. Column 80 extends upwardfrom base 52, and may optionally comprise a box steel structure. Slidingjoints 82 are counterbalanced by weights mounted with column 80. Sensors(typically in the form of potentiometers) indicate vertical position ofslider joints 82, and also indicate the rotational position of eachrotary joint 84. As the structure of the joint elements is known, theprocessor can accurately determine the position and orientation of themanipulator base. As the position of the tool and tool end effector willbe known relative to the manipulator base, the processor can furtheraccurately determine end effector position and orientation, as well ashow to effect movement in a desired direction by articulating one ormore the driven joints.

[0052] Each of rotational joints 84 and slider joints 82 includes abrake. The brake prevents articulation about the joint unless the brakeis released, the brake being normally on. The brakes at all the jointsare actuated in unison by a button on the set-up joints, therebyallowing the operating room personnel to position the manipulator inspace when the brake is released. Additional rotational joints similarlyallow the orientation of the manipulator to be set while the brake isreleased. The exemplary set-up joint structure is more fully describedin co-pending application Ser. No. 09/368,309, filed Aug. 3, 1999, thefull disclosure of which is incorporated herein by reference.

[0053] An alternative set-up joint structure is illustrated in FIG. 3A.In this embodiment, an endoscope 55 is supported by an alternativemanipulator structure 58′ between two tissue manipulation tools. Itshould be understood that the present invention may incorporate a widevariety of alternative robotic structures, including those described inU.S. Pat. No. 5,878,193, the full disclosure of which is incorporatedherein by reference. Additionally, while the data communication betweena robotic component and the processor of the robotic surgical system isprimarily described herein with reference to communication between tool54 and the processor of the robotic surgical system, it should beunderstood that similar communication may take place between circuitryof a manipulator, a set-up joint, an endoscope or other image capturedevice, or the like, and the processor of the robotic surgical systemfor component compatibility verification, component-type identification,component calibration (such as off-set or the like) communication,confirmation of coupling of the component to the robotic surgicalsystem, or the like.

[0054] An exemplary tool 54 is illustrated more clearly in FIG. 4. Tool54 generally includes a rigid shaft 102 having a proximal end 104 anddistal end 106. A proximal housing 108 includes an interface 110 whichmechanically and electrically couples tool 54 to the manipulator. Asurgical end effector 112 is coupled to shaft 102 by a wrist joint 114providing at least 1 degree of freedom, and ideally providing at least 2degrees of freedom.

[0055] As illustrated in FIG. 4A, a drive system 116 mechanicallycouples first and second end effector elements 112 a, 112 b to drivenelements 118 of interface 110. Drive system 116 is more fully describedin U.S. Pat. No. 5,792,135, the full disclosure of which is incorporatedherein by reference. Stated simply, the drive system translatesmechanical inputs from driven elements 118 into articulation of thewrist about first and second axes A1, A2, as well as into actuation ofthe two element end effector by relative movement of the end effectorelements about axis A2. In addition, driven elements 118 can effectrotation of the end effector about the axis of shaft 102 (A3) byrotating the shaft relative to proximal housing 108, and allowing thecables to twist (within a limited angular range) within the shaft.

[0056] A wide variety of alternative drive systems might be employed,including alternative cabling arrangements, drive chains or belts,hydraulic drive systems, gear trains, or the like. In some of thesedrive systems, motion of end effector 112 about the axes may be coupledto multiple driven elements 118. In other embodiments, there may be aone to one correspondence between driven elements 118 and motion of anend effector element about an axis. Still other embodiments may requirefewer (or more) driven elements to effect the desired degrees offreedom, for example, when a single element end effector is provided.Hence, manipulation of the end effector via interface 110 will generallyinvolve some reconfiguration of the robotic system during the toolchange. One alternative drive system 116′ is shown in FIG. 4B.

[0057] Exemplary wrist structures and surgical end effectors areillustrated in more detail in FIGS. 5A and 5B. A Potts scissor isillustrated in FIG. 5A, while a 15 degree scalpel electrically coupledto a conductor 120 for electrosurgery is illustrated in FIG. 5B. Thesedifferent tool-types have wrists 114 which may have differing separationdistances between their axes A1, A2, differing range of motions abouteach axes, different joint binding positions or singularities, and/orother differences in their axial geometries. Additionally, these twodifferent end effector structures will have different strengths,different inertias, different effective gearing ratios between motionabout their axes and movement of driven elements 118, and the like.Still further differences between these two tool-types, and/or betweeneither of these tools and tools of other types, include the presence orabsence of an electrosurgical capability, the useful life of the tool(in time, procedures, or tool change operations), the ability to replaceend effector elements, and the like. It should be understood thatalternative wrist joint arrangements are possible.

[0058] Still further end effectors for additional different tool-typesare illustrated in 5C-5H. FIG. 5C illustrates a DeBakey forceps, whileFIG. 5D illustrates a microforceps. Potts scissors are again illustratedin FIG. 5E, and a clip applier is illustrated in FIG. 5F. Anotherscalpel is illustrated in FIG. 5G, while FIG. 5H illustrates anelectrocautery probe. It should be understood that a wide variety ofalternative end effectors for differing tool-types may be provided, andthat several of these tool-types may be used during a single surgicalprocedure. Hence, the tools of the present invention may incorporate anyof the illustrated end effectors, or any other end effector which isuseful for surgery, particularly at an internal surgical site.

[0059] Interface 110 of a proximal housing 108 is illustrated in FIG. 6.As seen schematically in FIG. 4A, driven elements 118 provide mechanicalcoupling of the end effector to drive motors mounted to the manipulator.Driven elements 118 each include a pair of pins 122 extending from asurface of the driven element. An inner pin 122A is closer to an axis ofrotation of each driven elements 118 than an outer pin 122B, which helpsto ensure positive angular alignment of the driven element. Interface110 further includes an array of electrical connecting pins 124 coupledto a memory structure 126 by a circuit board within housing 108. In theexemplary embodiment, memory 126 comprises Dallas part No. DS 2505.

[0060] Surgical tools 54 will generally be sterile structures, oftenbeing sterilizable and/or being provided in hermetically sealed packagesfor use. In contrast, the complex servo mechanism of cart 50 andmanipulator 58 may be difficult and/or impossible to fully sterilizebetween procedures. Instead, a sterile drape will often cover at least aportion of the cart and manipulator structures to maintain the sterileenvironment around the patient.

[0061] As tools 54 will be removed and replaced repeatedly during manyprocedures, the tool holder could potentially be exposed tocontamination if the interface directly engages the tool holder. Toavoid contamination of the tool holder and possible cross contaminationbetween patients, the present invention provides an adaptor for couplinginterface 110 to the tool holder of the manipulator assembly.

[0062] White interface 110 is described herein with reference tomechanical, electrical, and magnetic coupling elements, it should beunderstood that a wide variety of telemetry modalities might be used,including infrared, inductive coupling, or the like.

[0063] Referring to FIGS. 7A-7E, adaptor 128 generally includes a toolside 130 and a holder side 132. A plurality of rotatable bodies 134 aremounted to a floating plate 136 which has a limited range of movementrelative to the surrounding adaptor structure normal to the majorsurfaces of the adaptor. Axial movement of the floating plate helpsdecouple the rotatable bodies from the tool when the levers along thesides of housing 108 are actuated (See FIG. 4).

[0064] Rotatable bodies 134 are resiliently mounted to floating plate136 by resilient radial members which extend into a circumferentialindentation about the rotatable bodies. The rotatable bodies can moveaxially relative to plate 136 by deflection of these resilientstructures.

[0065] When disposed in a first axial position (toward tool side 132)the rotatable bodies are free to rotate without angular limitation.However, as the rotatable bodies move axially toward tool side 130, tabs138 (extending radially from the rotatable bodies) laterally engagedetents on the floating plates so as to limit angular rotation of therotatable bodies about their axes. This limited rotation can be used tohelp drivingly engage the rotatable bodies with drive pins of theholder, as the drive pins will push the rotatable bodies into thelimited rotation position until the pins are aligned with (and slideinto) openings 140.

[0066] Openings 140 on the tool side 130 and holder side 132 ofrotatable bodies 134 are configured to accurately align the drivenelements 118 of the tool with the drive elements of the holder. Asdescribed above regarding inner and outer pins 122A, 122B of drivenelements 118, the openings 140 in each side of each rotatable body areat differing distances from the axis of rotation so as to ensure thatthe alignment is not 180° from its intended position. Additionally, eachof the openings 140 is slightly radially elongate so as to fittinglyreceive the pins in the circumferential orientation. This allows thepins to slide radially within the openings and accommodate some axialmisalignment between the tool and holder, while minimizing any angularmisalignment and backlash between the drive and driven elements.Openings 140 on the tool side 132 are offset by about 90° from theopenings on the holder side, as can be seen most clearly in FIG. 7C.

[0067] Holder side of adaptor 128 includes another array of electricalconnector pins 124, and the tool side 132 of the adaptor includes slots142 for receiving the pin array from the tool (as illustrated in FIG.6). In addition to transmitting electrical signals between the tool andholder, at least some of these electrical connections are coupled to anadaptor memory device 144 by a circuit board of the adaptor. A latch 145releasably affixes the adaptor to the holder. A lip on the tool side 130of adaptor 128 slidably receives laterally extending tabs of housing 108adjacent to interface 110. The interaction between pins 122 and openings140 helps restrain the tool in the engaged position until the leversalong the sides of the tool housing push the floating plate axially fromthe interface so as to release the tool. The holder 129 and driveelements 119 are shown (without the adjacent manipulator structure) inFIGS. 7F through M.

[0068] Referring now to FIG. 8, an exemplary circuit diagram illustratesthe coupling of tool memory 126 and adaptor memory 144 to the wiringharness of the manipulator. The electrically coupling of tool memory 126with the wiring of the manipulator may be used to sense the presence ofthe tool. Similarly, electrical coupling between the manipulator wiringsystem and adaptor memory 144 may be used as an adaptor engagementsensor. In the exemplary embodiment, two additional sensors are alsoprovided to determine engagement of the tool and holder: a magnetic reedswitch 147 (actuated by a magnet 125 of interface 110), and a electricalcoupling short 148 (or alternatively an end-of-life indicator)electrically coupling two of the pins 124 of tool 54. The use of amagnetically actuated sensor mounted to the holder or adapter isparticularly advantageous. The tool-mounted magnet will tend to maintainthe signal from a magnetic sensor (despite small, stress inducedmovements of the tool), in part because of the magnetic field effectsand/or hysteresis, once contact has been made. Optionally, adaptermemory 144 may be read only when no tool is coupled to the adapter by“shorting” the adapter memory with the magnetic reed switch, so that theadapter is transparent to tool/processor communications afterinstallation is completed.

[0069] An exemplary surgeon's workstation is illustrated in FIGS. 8A and8B. Control station 150 includes processors 152 for the robotic circlemechanism. Also included in controller station 150 are a stereo imagingsystem 154 and a pair of controllers (not shown).

[0070] The surgeon will generally manipulate tissues using the roboticsystem by moving the controllers within a three dimensional controllerwork space of controller station 150. Processor 152 can calculate animage capture coordinate system via the sensors in setup joints 56 andmanipulator 58 supporting the laparoscope, and can perform coordinatesystem transformations so as to generate signals to the drive motors ofthe manipulator that maintain alignment between the three dimensionalimage of the end effectors and the hand controllers within thecontroller work space. By maintaining this alignment, as the physicianmoves the hand controller in both position and orientation, the roboticsurgery system allows the surgeon to manipulate the surgical tools as ifthe handle in the surgeon's hand and the end effector in the surgeon'sfield of view define a single contiguous surgical instrument. Thisprovides an enhanced sense of presence and allows the surgeon to operateefficiently and accurately without performing mental coordinatetransformations. The program instructions for effecting these processesmay optionally be embodied in a machine readable code stored on atangible media 153, which may comprise an optical disk, a magnetic disk,a magnetic tape, a bar code, EEPROM, or the like. Alternatively,programming instructions may be transmitted to and from processor 152using data communications systems such as an IO cable, an intranet, theinternet, or the like. An exemplary control system is described in moredetail in co-pending U.S. patent application Ser. No. 09/373,678, filedAug. 13, 1999, for a Camera Referenced Cartesian Control System, thefull disclosure of which is incorporated herein by reference.

[0071] The tool/adaptor hardware signal path is schematicallyillustrated in FIG. 9. Processor 152 of master control station 150comprises multiple separate processor boards supported by a chassis. Inthe exemplary embodiment, a control and transform processor CTP handlescalculation of the coordinate system transforms for generating theproper instruction signals to send to servo motors. The control andtransform processor CTP may comprise an Analog Device ADSP 21060 digitalsignal processor, or a wide variety of alternative commerciallyavailable processors. A master diagnostic controller MDC monitors andverifies the health of the processing and servo mechanical system. Inthe exemplary embodiment, the master diagnostic controller MDC comprisesa Dallas DS 87C530 processor. A Dallas DS 87C520 processor is used asthe user interface master controller UMC to handle the input and outputto and from the surgeon seated at the console. Once again, thesefunctions may alternatively be performed by a variety of commerciallyavailable processors. Hence, processor 152 may include a singleprocessor, or a number of distinct processor structures coupledtogether, ideally in a distributed processing arrangement.

[0072] In the exemplary distributed processing arrangement shown in FIG.9, processor 152 makes use of a remote printed circuit assembly (“PCA”)referred to as the remote interface adaptor RIA, which is coupled to thechassis by a wiring harness. A remote interface adaptor RIA is providedfor each of the robotic arms of the system, typically including one PCAfor the endoscope and two PCA's for the two surgical end effectors. Theremote interface adaptor RIA also comprises a Dallas DS 87C520 processorand couples the processor 152 to the holder or carriage of manipulator58. The RIAs 56 perform local processing for the manipulators, set-upjoints, and/or tools, and communicate with processor 152 using ahigh-level language. Manipulator 58 is, in turn, coupled to tool 54 byadaptor 128 as described above.

[0073] It should be noted that reed switch 147 may actually be mountedon carriage of manipulator 58, and may be actuated by a magnet mountedon the tool 54. Hence, reed switch 147 ensures that tool 54 ispositioned in the holder of manipulator 58, the reed switch acting as atool sensor. Electrical coupling of the tool memory 126 and anelectrical loop-back circuit 149 connecting pins of tool 54 each act asadditional independent tool sensors. Optionally, an end-of-use detectorsuch as a low resistance timed fuse, or the like, may change anelectrical characteristic of the loop-back circuit to disqualify toolspast the end of their safe lives. An expired tool may provide anindication to the system operator such as a pop-up flag, a color-changespot, or the like, to indicate the tool is at or near the end of itslife. Optionally, a portable life indication device may be coupled tothe tools before each procedure to determine if the tool has sufficientlife to be used for the planned procedure.

[0074] A variety of alternative end of use indication systems might beprovided to indicate that a tool is near or at the end of its usefullife. For example a mechanical end of use indicator may be mounted inhousing 108, such as a colored button or tab which can pivot into viewthrough an indication window of the housing. Such a button might bebiased toward the viewable position, and initially held out of sight bya latch. The latch might be releasable by an actuator mounted to thecarriage of manipulator 58, for example, by the movement of a plunger ofa solenoid on the manipulator. The sterile adapter or drape willpreferably accommodate movement of such a plunger while maintainingsterile separation between the manipulator and tool. In general,providing a mechanical indicator on the tool for actuation by anactuation means of the manipulator can avoid the cost for end of useactuators mounted on each tool.

[0075] Referring now to FIG. 10, the flow of the tool signals from thetool sensors during a tool change operation originates from theinteraction between the remote interface adaptor RIA and the toolitself. The tool signals are transmitted per procedure management/datahandler programming running on the master diagnostic controller MDC. Theoverall logic flow proceeds according to a supervisor program running onthe user interface master control UMC according to the surgeon's inputfrom the master console.

[0076] The supervisor directs the state of the robotic arms, and alsoperfects coupling between a mounted tool 54 and the holder of amanipulator by driving the servo motors in a predetermined manner, asshall be explained below. The supervisor software directs movement ofthe tool through a middleman program running on the control andtransform processor CTP. The middleman program accepts instructions fromthe supervisor to move the surgical end effectors in the desireddirection, for example, and calculates the drive signals to be providedto the servo motors so as to effect that desired motion. In other words,the middleman program transforms the workstation space instruction intoajoint space servo signal set for the servo motors to drive the endeffectors.

[0077] It should be understood that the coordinate transformations usedby the middleman to calculate the required servo signals will vary asthe relationship between the field of view from the endoscope and thesurgical end effectors varies. Deriving these coordinate transformationsis well described in the patent literature, for example, in U.S. Pat.No. 5,696,837 and U.S. patent application Ser. No. 09/373,678, the fulldisclosures of which are incorporated herein by reference. In thecontrol method illustrated in FIG. 10, a Kernel program running on thecontrol and transform processor CTP and Compute Engine processors CE'sderives these transformations based on the information provided by theposition sensors at the setup joints, manipulators, and the like.

[0078] Referring now to FIGS. 11 and 12, processor 152 changes theoperating state of the robotic system based on tool signals from thethree tool engagement sensors (reed switch 147, tool memory 126, and endof use/pin short circuit 148) and an adaptor signal sensed by couplingwith the adaptor memory 144. In the local tool detection procedureillustrated in FIG. 11 (which is performed at the remote interfaceadapter RIA with a cycle time of 35 milliseconds) the reed switch andadapter memory are first sensed to check for the presence of theadapter. So long as the adapter is present, the system then checks forthe presence of the tool based on coupling with the tool memory 126. Thepresence or absence of the tool is verified by checking for the end ofuse or pin short circuit 148 of the tool breadboard. The remoteinterface adapter RIA transmits the sensed signals from the sensor scanto the master digital controller MDC for use by the ProcedureManagement/Data Handler software.

[0079] As can be understood with reference to FIG. 12, if the sterileadapter is not sensed (either upon start up or while the tool isremoved), the robotic system remains in a sterile adapter off operatingstate S1. Once the sensor scan indicates that adapter 128 is present,program management data handler advances the operating state to a secondoperating state S2 in which the system is awaiting engagement ofinterface 110 with the holder of the manipulator. If the signal from theadapter memory chip is lost for more than half a second, the systemreturns to the adapter off state S1.

[0080] If at least one signal from the three tool sensors indicatesengagement of the tool, the operating state advances to a Tool BeingInserted mode S4, and upon agreement of all three sensors that the toolis fully mounted on the holder, the system enters a Tool Is On operatingstate S5 in which manipulation of the end effectors by the surgeon maybe enabled.

[0081] The elongate shafts of tool 54 can induce significant mechanicalstresses between interface 110, adapter 128, and the holder of themanipulator. As a result, one or more of the tool signals may be lost atleast temporarily. If tissue manipulation were halted each time a toolsignal were lost, the operation would be significantly delayed and totalrisk to the patient would increase. The present system takes advantageof the redundant tool signals by keeping the system in the Tool Is Onoperating state S5 despite the loss of one or even two tool signals. Ifthe loss of signal persists for more than a threshold time, the signalloss is stored for diagnostic purposes. Nonetheless, the system remainsin the operating state, until all three tool signals indicate the toolis removed, at which point the system drops down to the Tool Is Outoperating state S2. This procedure provides a much more robust approachthan analyzing each tool signal independently.

[0082] Referring now to FIG. 13, the instructions generated by thesupervisor software running on the user interface master controller UMCas a result of the changes in state during a tool change procedure willgenerally follow one of four paths. If the adapter is not present and atool has been taken off (or no tool and adapter are present at startup), the supervisor notifies the user, for example, by displaying anicon on the stereo display and/or assistance monitor, per path PA. If anadapter has been mounted to the holder and no tool is engaged, thesupervisor initiates manipulations of the driving elements of the holderwhich perfect mechanical coupling of the rotational bodies of adapter128 with the driving elements of the holder per path PB.

[0083] As described in some detail with reference to FIGS. 7A through E,rotatable bodies 134 can move axially relative to a floating plate 136.Prior to perfecting mechanical coupling between the holder driveelements and the rotatable bodies, pins of driving elements (which aresimilar in configuration to the driven elements 118 of interface 110)will push the rotatable bodies away from holder side 132 of adapter 128and toward tool side 130. In this rotationally limited axial position,tabs 138 of rotatable bodies 134 engage detents of the floating plate soas to prevent rotation of more than about 90°. This can ensure that thepins of the driving elements rotate relative to the rotatable bodies bydriving the servo motors of the manipulator by more than 90°.

[0084] In the exemplary tool change engagement path PB, the servo motorsof the manipulator are driven from a starting central position so as torotate the drive elements by 180° in a first direction (for example,clockwise) in step ENGAGESA1. As the pins of the driving elements willonly enter opening 140 of rotatable bodies 134 in a single angularorientation, it is possible that this step will be insufficient toperfect mechanical coupling. To ensure that coupling is complete, thesupervisor therefore initiates rotation of the servo motors so as toturn the driving the elements by 360° in the opposite direction (in ourexample, counterclockwise) in step ENGAGESA2. At some point during theabove two steps, pins 122 of the driving elements will be aligned withopenings 144 of rotatable bodies 134 and the openings will receive thepins, thereby allowing the rotatable body to move axially to the freelyrotatable position. The driving elements in rotatable bodies are thencentered in their range of angular travel in step ENGAGESA3.

[0085] Once the steps of path PB have been performed so as to perfectmechanical coupling of the driving elements of the holder with therotatable bodies of the adapter 128, the supervisor directs the systemto perform the procedure outlined by the second part of path PB.Basically, the driving elements (and rotatable bodies) are centered andcentering is verified in preparation for mounting of a tool to theholder by rotating the servos right to their end of travel, left, andthen halfway between under steps TOOLPREP1, 2, and 3, respectively.These centering and verification steps are also performed if a tool hasbeen removed from the holder, per path PC.

[0086] In the final alternative procedure which will be described withreference to FIGS. 13, mounting of a tool on the adapter and holderresults in the steps outlined in path PD. First, the system verifiesthat the tool is of the type which is allowable for use on thisparticular robotic surgical system. To determine compatibility,circuitry of the tool may send a signal indicating the tool-type toprocessor 152. More specifically, data stored in tool memory 148 may betransmitted to the processor. In the exemplary embodiment, the data fromthe tool memory will include a character string indicating toolcompatibility with the robotic system. Additionally, the data from thetool memory will often include a tool-type. In some embodiments, thedata will also include tool offset calibration information. This datamay be provided from the tool memory 148 in response to a request signalfrom the processor 152. A simplified version of path PD is performed ifa camera is changed, as shown.

[0087] Tool-type data will generally indicate what kind of tool has beenattached in a tool change operation. For example, the tool-type datamight indicate that Potts scissors or a scalpel has been attached to theholder. The tool-type data may include information on wrist axisgeometries, tool strengths, grip force, the range of motion of eachjoint, singularities in the joint motion space, the maximum force to beapplied via driven elements 118, the tool transmission systemcharacteristics including information regarding the coupling of drivenelements 118 to articulation of an associated (or the interactingplurality of associated) joint motion, servo gains, end effectorelements speeds, and the like.

[0088] Tool-type data may optionally be stored in memory of the roboticsystem. The signal from the tool may comprise an identifier referencingthe relevant portion of data from the look-up table. This tool-type datamay be loaded into a memory of processor 152 by the system manufacturer,the look-up table preferably being in the form of a flash memory,EEPROM, or the like. As each new tool-type is provided, the roboticsystem manufacturer can then revise the look-up table to accommodate thenew tool-specific information. It should be recognized that the use oftools which are not compatible with the robotic surgery system, forexample, which do not have the appropriate tool-type data in aninformation table, could result in inadequate robotic control over theend effector by both processor 152 and the surgeon.

[0089] In addition to the tool-type data indicated by the signals fromtool 54, tool specific information may be stored in the tool memory 148for reconfiguring the programming of processor 152. For example, therewill often be some measurable misalignment or offset between andintended relationship between the wrist joint and end effector elementsand the positions of driven elements 118. To accommodate thismisalignment without degrading the accuracy of the robotic control overthe end effectors, the measured offsets may be stored in the tool memoryand factored into the transforms generated by the Kernel. Hence, thestoring of such calibration information can be used to overcome minormechanical inconsistencies between tools of a single type. As describedabove, tool life and cumulative tool use information may also be storedon the tool memory and used by the processor to determine if the tool isstill safe for use. Total tool life may be measured by clock time, byprocedure, by the number of times the tool has been loaded onto aholder, and even by individual numbers of end effector actuations. Toollife data will preferably be stored in the memory of the tool using anirreversible writing process.

[0090] To perfect mechanical coupling between the driving elements ofthe holder (and the previously coupled rotatable bodies 134 of adapter128), the supervisor initiates a “turn one way, turn the other way, andcenter” operation similar to that described above. To limit the range ofmotion of driven elements 118 and ensure pins 122 enter openings 140 ofadapter 128, the holder may move axially to a proximal position so thatthe end effector is disposed within cannula 72 of manipulator 58 (seeFIG. 2B). The axial positioning and rotation (turn, turn, and center) ofthe end effector are performed under steps ENGAGETOOL1-4, respectively.

[0091] The tool-type (and preferably tool-specific) data from toolmemory 148 and/or the look-up table is sent to the middleman and/orKernel software running on the coordinate transformation processor CTPfor driving the appropriate coordinate transformations and generatingthe servo drive signals, as generally described above with reference toFIG. 10. The supervisor may then verify operation of the tool bymanipulating the end effector per the calculated transforms, so as tocomplete the steps of path PD.

[0092] Methods for mounting adaptor 128 (together with a sterile drape)to the holder of manipulator 58 can be understood with reference toFIGS. 14A and B. Subsequent mounting of tool 54 to adapter 128 generallycomprises inserting the surgical end effector distally through cannula72 and sliding interface 110 of tool 54 into engagement with a mountedadapter, as illustrated in FIG. 14C. The tool can be removed andreplaced by reversing the tool mounting procedure illustrated in FIG.14C and mounting an alternative tool in its place.

[0093] Referring now to FIG. 15, an exemplary system and method forverifying compatibility of a tool with a robotic surgical system makesuse of a unique identification data string that is irreversibly storedon an integrated circuit included in the circuitry of a tool or othercomponent of the robotic surgical system. Advantageously, producers ofsuch integrated circuits can include this unique identification datastring on each integrated circuit such that no two integrated circuitsinclude the same identification data. For example, Dallas DS 2505 mayinclude a unique 64 bit identification data string which differs fromthe data strings of every other circuit of that part number.

[0094] The identification data string could be downloaded directly tothe processor and compared with a table listing all identification datastrings of circuits included in compatible tools. Such a table couldthen be updated each time additional tools were fabricated or outdatedtools were retired.

[0095] To avoid continuously updating a compatible tool table, averification data string 164 may be calculated from the uniqueidentification data according to an algorithm 166. Algorithm 166 may beused as an encryption mechanism, typically using an arbitrary functionwhich cannot easily be determined by sampling verification data andidentification data from a few tools. Verification data string 164 maythen be stored in a memory of the tool or other robotic component duringtool production, typically using a non-volatile memory.

[0096] When the tool having identification data 162 and verificationdata 164 is coupled to the robotic surgical system, a signal 168including these data strings may be transmitted to processor 152 asdescribed above. By including a tangible media with method steps forperforming algorithm 166 in a system accessible by processor 152, theprocessor can also perform the algorithm on the unique identificationdata so as to derive a conformation data string 170. This can becompared with the verification data, thereby confirming compatibility ofthe tool with the robotic system. Algorithm 166 may include any of awide variety of known encryption algorithms, or may be developedspecifically for use in the robotic surgical system of the presentinvention.

[0097] The descriptions given above regarding the exemplary devices,systems, and methods of the present invention are provided by way of anexample, and for clarity of understanding. A wide variety of changes,modifications, and adaptations of these specific embodiments will beobvious to those of skill in the art. Hence, the invention is limitedsolely by the following claims.

What is claimed is:
 1. A robotic surgical tool for use in a roboticsurgical system having a processor which directs movement of a toolholder, the tool comprising: a probe having a proximal end and a distalend; a surgical end effector disposed adjacent the distal end of theprobe; an interface disposed adjacent the proximal end of the probe, theinterface releasably coupleable with the tool holder; and circuitrymounted on the probe, the circuitry defining a signal for transmittingto the processor so as to indicate compatibility of the tool with thesystem.
 2. The robotic surgical tool of claim 1, further comprising asterile adapter releasably mounted to the tool holder, the adaptercoupling the tool holder to the interface, wherein the circuitrytransmits the signal to the processor of the robotic surgical system viathe adapter.
 3. The robotic surgical tool of claim 1, wherein the signalcomprises unique tool identifier data.
 4. The robotic surgical tool ofclaim 3, the processor of the robotic surgical system includingprogramming to manipulate the tool identifier according to apredetermined function so as to derive verification data in response tothe tool identifier, wherein the signal transmitted to the processorfurther comprises the verification data.
 5. The robotic surgical tool ofclaim 1, wherein the signal comprises an identifier signal included in atable accessible to the processor for comparison with the signal, thetable comprising a plurality of compatible tool identification signals.6. The robotic surgical tool of claim 1, wherein the signal comprises anarbitrary compatibility data string.
 7. The robotic surgical tool ofclaim 1, wherein the probe body comprises an elongate shaft suitable fordistal insertion via a minimally invasive aperture to an internalsurgical site of a patient body.
 8. The robotic surgical tool of claim1, wherein the end effector is adapted for manipulating tissue, andfurther comprising a wrist joint coupling the end effector to the shaftfor varying an orientation of the end effector within the internalsurgical site.
 9. The robotic surgical tool of claim 1, wherein the endeffector defines a field of view, the probe comprising an image capturedevice.
 10. A robotic surgical component for use in a robotic surgicalsystem having a processor and a component holder, the componentcomprising: a component body having an interface mountable to thecomponent holder, the body supporting a surgical end effector; a drivesystem coupled to the body, the drive system moving the end effector inresponse to commands from the processor; and circuitry mounted on thebody, the circuitry defining a signal for transmitting to the processor,the signal comprising at least one member selected from the groupconsisting of compatibility of the component with the system, acomponent-type of the component, coupling of the component to thesystem, and calibration of the component.
 11. The robotic surgicalcomponent of claim 10, wherein the component comprises a tool includinga shaft having a proximal end and a distal end, the end effectordisposed adjacent the distal end of the shaft, with a plurality ofdegrees of motion relative to the proximal end of the shaft, and whereinthe interface comprises a plurality of driven elements, and furthercomprising a tool drive system coupling the driven elements to thedegrees of motion of the end effector, the tool drive system having oneor more calibration offsets between a nominal position of the endeffector relative to the driven elements and a measured position of theend effector relative to the driven elements; wherein the circuitrycomprises a memory storing data indicating the offsets, the memorycoupled to the interface so as to transmit the offsets to the processor.12. A robotic surgical tool for use in a robotic surgical system havinga processor which directs movement of a tool holder, the toolcomprising: a probe having a proximal end and a distal end; a surgicalend effector disposed adjacent the distal end of the probe; an interfacedisposed adjacent the proximal end of the probe, the interfacereleasably coupleable with the tool holder; and circuitry mounted on theprobe, the circuitry transmitting a signal via the interface to theprocessor so as to indicate a tool-type of the tool.
 13. The tool ofclaim 12, further comprising at least one joint disposed between theinterface and end effector, the joint defining a joint axis geometry,and wherein the signal indicates the joint geometry of the tool to theprocessor.
 14. The tool of claim 12, wherein the end effector has astrength, and wherein the signal indicates the strength of the endeffector to the processor.
 15. A robotic surgical tool for use in arobotic surgical system having a processor which directs movement of atool holder, the tool comprising: a probe having a proximal end and adistal end; a surgical end effector disposed adjacent the distal end ofthe probe; an interface disposed adjacent the proximal end of the probe,the interface releasably coupleable with the tool holder; and circuitrymounted on the probe, the circuitry transmitting a signal via theinterface to the processor so as to indicate tool calibration offsets ofthe tool.
 16. A method for installing a robotic surgical component in arobotic surgical system, the method comprising: mounting the componentto a component holder; transmitting a signal from the component to aprocessor of the robotic surgical system; articulating the component inresponse to the signal per commands of the processor.
 17. Theinstallation method of claim 16, further comprising verifyingcompatibility of the component with the robotic surgical system usingthe signal.
 18. The installation method of claim 17, wherein thecompatibility verification step comprises: providing uniqueidentification data on the component; deriving verification data fromthe identification data according to an algorithm and storing theverification data in a memory of the component, the signal comprisingthe identification and verification data; performing the algorithm onthe transmitted unique identification data with the processor andcomparing the results with the verification data.
 19. The installationmethod of claim 16, further comprising reconfiguring the commands of theprocessor in response to the signal.
 20. The installation method ofclaim 19, wherein the signal comprises a component-type of thecomponent.
 21. The installation method of claim 20, wherein the signalcomprises calibration of the component.
 22. A robotic surgical systemcomprising: a plurality of tools of different tool-types, each toolcomprising an elongate shaft with a cross section suitable forintroduction into an internal surgical site within a patient body via aminimally invasive opening, a distal surgical end effector coupled tothe shaft by at least one joint, the joint drivingly coupled to aproximal interface by a tool drive system, and circuitry that transmitsa tool-type signal via the interface; a robotic manipulator including alinkage supporting a tool holder which releasably receives theinterface, at least one manipulator drive motor drivingly engaging thelinkage so as to move the tool holder relative to the opening andposition the shaft within the surgical site, and at least one tool drivemotor coupled to the tool holder so as to drivingly engage the tooldrive system and articulate the at least one joint; and a processorcoupled to the tool holder, the processor having programming thateffects a desired movement of the end effector by transmitting drivesignals to the at least one tool drive motor of the manipulator, whereinthe processor reconfigures the program for the different characteristicsbased on the tool-type signals.
 23. The robotic system of claim 22,wherein the drive systems of the different tool-types effect differentangular movement about the joints for a given input from the tool drivemotors, and wherein the processor reconfigures the program for thedifferent drive system angular movements.
 24. A fault tolerant roboticsurgical system comprising: a surgical tool having a surgical endeffector and an interface; a manipulator assembly having a base and atool holder for releasably engaging the interface; a plurality of toolengagement sensors coupled to the tool holder, each sensor producing atool signal when the interface engages the holder; and a processorcoupled to the tool engagement sensors, the processor having a toolchange mode and a tissue manipulation mode, the processor requiring toolsignals from each of the sensors before changing from the tool changemode to the tissue manipulation mode, the processor remaining in thetissue manipulation mode when at least one, but not all, of the toolsignals is lost.
 25. A robotic surgical system comprising: a manipulatorassembly having a base and a tool holder which moves relative to thebase, the tool holder having a plurality of drive elements; a steriledrape covering at least a portion of the manipulator; a sterile toolhaving a proximal interface and a distal end effector, the distal endeffector having a plurality of degrees of motion relative to theproximal interface, the degrees of motion coupled to driven elements ofthe interface; and an adapter disposed adjacent the sterile drapebetween the holder and the interface, the adapter comprising a pluralityof movable bodies, each movable body having a first surface driven bythe drive elements and a second surface driving the driven elements. 26.The robotic surgical system of claim 25, wherein the movable bodies arerotatable about an axis between the first and second surfaces, therotatable bodies movable between first and second axial positions, therotatable bodies being disposed in the first axial position when theadapter plate is mounted to the manipulator and the rotatable bodies aremisaligned with the drive elements, angular rotation of the rotatablebodies being limited when the rotatable bodies are disposed in the firstaxial position to allow alignment of the drive elements with therotatable bodies by rotating the drive elements, the rotatable bodieshaving unlimited angular rotation when the rotatable bodies are alignedwith the drive elements and the rotatable bodies are disposed in thesecond axial position, and wherein each of the driven elements has alimited angular rotation.
 27. A robotic surgical tool for use with arobotic manipulator having a tool holder, the tool holder havingmagnetically actuatable circuitry, the tool comprising; a probe having aproximal end and a distal end; a surgical end effector adjacent thedistal end of the probe; an interface adjacent the proximal end of theprobe, the interface releasably coupleable with the holder, theinterface comprising a magnet positioned so as to actuate the circuitryof the holder.
 28. A robotic surgical system comprising: a processor; atool having a surgical end effector; and a robotic manipulator couplingthe tool to the end effector; wherein the processor senses coupling ofthe tool to the manipulator by at least one member selected from thegroup consisting of: a signal from a memory circuit of the tool; asignal from a memory circuit of an adapter coupling the tool to themanipulator; and a signal from a magnetic switch that is magneticallyactuated by a magnet of the tool.
 29. A robotic system comprising: arobotic manipulator having a tool holder, the manipulator moving theholder in response to signals from a processor; a tool having a surgicalend effector; an adapter coupling the tool to the holder, the adaptermaintaining sterile separation between the tool and holder; a firstsensor disposed adjacent the holder, the first sensor transmitting afirst signal to the processor in response to coupling of the adapter tothe holder; and a second sensor disposed adjacent the holder, the secondsensor transmitting a second signal to the processor in response tocoupling of the tool to the adapter.
 30. The robotic surgical tool ofclaim 3, wherein the signal further indicates at least one of tool lifeand cumulative tool use by a measurement selected from the groupconsisting of calendar date, clock time, number of surgical procedures,number of times the tool has been coupled to the system, and number ofend effector actuations.
 31. A robotic surgical system comprising: atool having circuitry containing verification information; a coupler forcoupling the tool; and at least one system processor for receiving theverification information from the tool coupled to the coupler, said atleast one processor further manipulating the information with analgorithm to produce output information, comparing the outputinformation to predetermined data to verify compatibility of the toolwith the robotic surgical system, and enabling the robotic surgicalsystem to manipulate the tool if the output information matches thepredetermined data.
 32. The system of claim 31, wherein saidverification information and said predetermined data are unique to saidtool, and said predetermined data are contained in said circuitry onsaid tool.